Laminated roof construction and method of making same

ABSTRACT

A laminated roof construction and a method of forming the same wherein the roof comprises a supporting deck having a water-proof intermediate membrane upon which is superimposed a heat resistant sandwich-type foam panel. The foam panel consists of a cellular foam-like material such as polyurethane and similar substances, and this foam material has a top and bottom skin or film adhered to the foam. At least the top skin is weatherproof and is resistant to actinic rays.

Uited States Patent 1 Coglianese et al.

[ 51 Apr. 10, 1973 LAMINATED ROOF CONSTRUCTION AND METHOD OF MAKING SAME lnventors: Fred A. Coglianese, l-lackettstown; James J. Sullivan, Mendham, both of NJ.

Assignee: Millmaster Onyx Corporation, New

York, NY.

Filed: Sept. 8, 1971 Appl. No.: 178,557

US. Cl. ..161/161, 156/71, 156/304,

161/37, 161/40, 161/160 Int. Cl. ..B32b 3/26, E04b 2/00 Field of Search ..156/71, 304;

[5 6] References Cited UNITED STATES PATENTS 3,345,246 10/1967 Sheahan ..l61/16l 3,466,222 9/ l 969 Curtis t 161/160 3,492,196 1/1970 Moore ..16l/l60 Primary Examiner-William J. Van Balen Attorney-Arthur A. Jacobs 57] ABSTRACT A laminated roof construction and a method of forming the same wherein the roof comprises a supporting deck having a water-proof intermediate membrane upon which is superimposed a heat resistant sandwichtype foam panel. The foam panel consists of a cellular foam-like material such as polyurethane and similar substances, and this foam material has a top and bottom skin or film adhered to the foam. At least the top skin is weatherproof and is resistant to actinic rays.

21 Claims, 2 Drawing Figures PATENTEDAPR 1 0197s INVENTOR S FRED A.COGLIANESE F I G. 2.

JAFES J.SULL|\AN MaM ATTORNEY LAMINATED ROOF CONSTRUGTHON AND METHOD OF MAKING SAME This invention relates to a roof construction and to a method of making such roof construction, and it particularly relates to an insulated, laminated type of roof construction.

It was, heretofore, the general practice to utilize a system which comprises a roof deck consisting of metal, wood, concrete or gypsum on which an adhesive is hot-mopped, and on which a foam insulating layer is superimposed. The foam layer is then covered with a water-proof membrane consisting of asphalt felt composition, hot mopped with bitumen as a final step in water-proofing. Gravel is then used as a cover material. The disadvantages of this system,'as compared with the system of the present invention, are:

1. The water-proof membrane is directly exposed to light degradation, thermal shock, expansion and contraction under sun radiation.

2. Gravel is required for heat distribution to prevent overheating the felt.

3. Leak repair is difficult and expensive because of the need to remove gravel and insulation.

4. Roof loading is greater because of the use of gravel.

It is, therefore, one object of the present invention to overcome the above and other defects of prior roof constructions by providing a laminated roof construction which is resistant to light degredation, thermal shock, and undue expansion and contraction under solar radiation.

Another object of the present invention is to provide a roof construction of the aforesaid type which eliminates the necessity for using gravel or the like, and which is, therefore, lighter in weight.

- Another object of the present invention is to provide a roof construction of the aforesaid type which is relatively easy and inexpensive to repair.

Another object of the present invention is to provide a laminated roof construction of the aforesaid type which is relatively inexpensive and which is relatively easy to manufacture and to apply.

Other objects and many of the attendant advantages of this invention. will be readily. appreciated as it becomes better understood by reference to the followingdescription when read in conjunction with the .ac-

companying drawings wherein:

FIG. 1 is a perspective view of a roof construction with parts broken away.

FIG. 2 is a perspective view similar to FIG. 1 but showing an alternative form of the invention.

Referring now in greater detail to the figures of the drawing wherein similar reference characters refer to similar parts, there is shown in FIG. 1 a fragmentary portion of a roof construction, generally designated 10, which comprises a roof deck 12, made of either wood, metal, or a poured or precast concrete, gypsum board, plywood or any similar desirable rigid material.

On the upper surface of the deck 12 is provided a water-proof membrane 14. The membrane 14, as shown, is a pre-formed, l-ply sheet fabricated from an elastomeric polymer such as ethylene-propylene rubber, Neoprene, styrene-butadiene rubber, etc.; or it may be fabricated from thermoplastic materials such as polyvinyl-chloride, polycarbonate, acrylonitrile-butadiene-styrene, stabilized polyolefins, polyvinyl chloride-polyacrylate alloys, Tedlar, etc. This membrane 14 is adhered to the upper surface of the deck 12 by any desirable adhesive 16.

The membrane 14 is water-impermeable and acts as a very effective waterproofing agent for the roof.

Connected to the upper surface of the membrane 14, by means of an adhesive layer 18, is a heat insulating layer. This layer comprises a so-called foam sandwich panel fabricated from a sheet of foamed polymer 20, preferably but not necessarily polyurethane. The center sheet 20 of foamed polymer is provided with an upper and lower skin, respectively designated 22 and 24. The foam sheet 20 may be of any suitable thickness, usually between about 0.5 inch and about 2 inches. The skins 22 and 24 may either be of the same or different materials. However, among the preferable materials for the lower skin 22 are, for example, metal foil such as aluminum, paper-reinforced metal foil, kraft paper, roofing felt, dimensionally stable polymeric films, or any other suitable material. The upper skin 24 may be of the same material or may be of such materials as supported fluoroplastics, for example, coated on metal foil, paper, or other suitable backing, such, for example as polytetrafluoroethylene, fiuorinated ethylenepropylene, chlorotrifluoroethylene and polyvinylidenefluoride. These fluoroplastic materials are especially resistant to both actini'c rays and chemical action. In addition to these fluoroplastic materials, other materials may be used such as, for example, polyvinylchloride and the like.

The layer 20 is preferably constructed by prefabrication whereby the foam is extruded between the upper and lower skins while held against lateral foaming by opposed side walls. During the foam-forming and polymerization process, the foam sheet becomes integrally connected to the upper and lower skins- Although, as indicated above, polyurethane foam is preferred for the heat layer, other cellular foam materials may be substituted, as, for example, cellular polyvinyl chloride, polyolefins, polystyrene, styreneacrylonitrile copolymer, styrene-methylmethacrylate copolymer, etc. In all instances, however, it is required that the foam be sandwiched between upper and lower skins or films such as indicated at 22 and 24. The use of the sandwich construction for the foam layer obviates the necessity forusing such heavy inorganic mineral protective layers such as gravelland the like, but results in at least as good and, in most instances, better protection for the laminated roof construction. It is also less expensive and simpler to construct roofs of this type.

The adhesive layers 16 and 18 may comprise such suitable agents as Neoprene, natural rubber, blends of natural and synthetic rubber, epoxy resin, polyurethane, polyacrylate, asphalt, polysulfide and the like.

The membrane 14 has been described above as being constructed of a prefabricated elastomeric or thermoplastic sheet. However, it is also possible, and often preferable, to apply this membrane in the form of a liquid precursor, either by spraying, troweling, etc. This precursor subsequently polymerizes in situ to form the waterproof membrane. The precursor may comprise any one of a yariety of elastomeric or non-elastomeric substances, including either thermoplastic or thermosetting polymerizable substances, as for example, polysulfide, silicone polymers and the like.

Alternatively, the liquid precursor may be already polymerized but carried in solution or emulsion form. These may be in solution in appropriate solvents. Among the solvents which may be used on aromatic or aliphatic hydrocarbons; low molecular weight alcohols, preferably C to C ketones such as methyl isobutyl ketone'; glycols such as ethylene glycol monoethyl ether; esters; such as butyl acetate; or mixtures thereof.

When used in emulsion form, it is usually in aqueous emulsion, with or without other water-miscible solvents which are used for the purpose of increasing the freezethaw stability.

Alternatively, a liquid emulsion of a precursor of an elastomeric, thermoplastic or thermosetting polymer may be applied to form the waterproof layer on drying.

When the membrane 14 is applied in the form of a precursor or emulsion thereof, which cures or dries in situ, the adhesive layers 16 and 18 are omitted since the precursor or its emulsion acts as its own adhesive.

In FIG. 2, there is shown an alternative embodiment of the invention, wherein the roof construction is similar to the construction shown in FIG. 1, in that there is a roof deck 102 adhered to a membrane 104 by an adhesive 106.

The membrane 104'is adhered by an adhesive 108 to the bottom skin 110 of a foam layer 112 having a top skin 114.

All the parts of the construction of FIG. 2 may be substantially the same as in FIG. 1 except for the membrane 104. In this construction, the membrane 104 is a multi-layer assembly of alternate layers or plies of roofing felt and bitumen, the top and bottom plies being bitumen. In this case, the adhesive layers 106 and 108 are preferably bitumen.

It is also within the scope of the present invention to use mechanical attachment means such as screws, clamps, rivets, anchors, pins and studs and the like, in conjunction within the adhesive layers in all embodiments; or even to use such mechanical means in place of the adhesive.

It is also contemplated that the prefabricated foam sandwich panels would be used as separate sheets which are joined end-to-end by a suitable sealant or by tapes which are adhered over the joints. v r

The invention claimed is: v

1. A laminated roof construction comprising a supporting roof deck, a water-impermeable membrane superimposed on said roof deck, and a heat and actinic ray-resistant panel superimposed on said membrane,

said panel comprising a rigid cellular foam body having a top and bottom skin adhered to its respective upper and lower surfaces, at least the top skin being weatherresistant and substantially impervious to actinic rays.

2. The construction of claim 1 wherein the water proofing membrane is an elastomeric polymer.

3. The construction of claim 2 wherein the elastomeric polymer is a solidified elastomeric precursor which has been polymerized in situ.

4. The construction of claim 2 wherein the elastomeric polymer is a solidified liquid emulsion of an elastomeric precursor which has been polymerized in situ.

5. The construction of claim 2 wherein the the solvent.

6. The construction of claim 2 wherein the elastomeric polymer is a pre-polymerized emulsion polymer which forms the membrane by evaporation of the carrier.

7. The construction of claim 1 wherein the waterproof membrane is a thermoplastic material.

8. The construction of claim 1 wherein the membrane comprises alternate layers of felt and bitumen.

9. The construction of claim 1 wherein the foam is polyurethane.

10. The construction of claim 1 wherein the top skin is a fluoropolymer film.

11. The construction of claim 1 wherein the top skin is a member of the group consisting of metal foil and metal kraft paper laminates.

12. The construction of claim 1 wherein the bottom skin is adhered is the membrane by an adhesive selected from the group consisting of neoprene, natural rubber, blended natural and synthetic rubber, epoxy resin, polyurethane and polyacrylate, polysulfide, silicone rubber, and asphaltic blends.

13. A method of making an insulated laminated roof which comprises positioning a roof deck in place, ad-

hering a water-impermeable membrane in superimposed position on said roof deck, and adhering a heat and actinic ray-resistant panel in superimposed position on said membrane, said panel being of foam interior construction and having adherent skins on its upper and lower surfaces.

14. The method of claim 13 wherein said membrane is formed by applying an elastomeric precursor to the upper surface of the roof deck, and then polymerizing said precursor in situ.

15. The method of claim 13 wherein said membrane is formed by applying a liquid emulsion of an elastomeric precursor to the upper surface of the roof deck and polymerizing said liquid emulsion in situ.

16. The elastomeric of claim 13 wherein said membrane is formed by applying a solution of a prepolymerized elastomeric precursor to the upper surface of the roof deck, and then evaporating the solvent.

17. The method of claim 13 wherein said membrane is formed by applying an emulsion of a pre-polymerized elastomeric precursor to the upper surface of the roof deck, and then evaporating the carrier.

18. The method of claim 13 wherein an adhesive is applied between the upper and lower surfaces of the membrane and the respective panel and roof deck.

19. The method of claim 13 wherein the membrane is applied as a liquid precursor and forms its own adherent to the panel and roof deck as it polymerizes or 

2. The construction of claim 1 wherein the water-proofing membrane is an elastomeric polymer.
 3. The construction of claim 2 wherein the elastomeric polymer is a solidified elastomeric precursor which has been polymerized in situ.
 4. The construction of claim 2 wherein the elastomeric polymer is a solidified liquid emulsion of an elastomeric precursor which has been polymerized in situ.
 5. The construction of claim 2 wherein the elastomeric polymer is a pre-polymerized solution polymer which forms the membrane by evaporation of the solvent.
 6. The construction of claim 2 wherein the elastomeric polymer is a pre-polymerized emulsion polymer which forms the membrane by evaporation of the carrier.
 7. The construction of claim 1 wherein the waterproof membrane is a thermoplastic material.
 8. The construction of claim 1 wherein the membrane comprises alternate layers of felt and bitumen.
 9. The construction of claim 1 wherein the foam is polyurethane.
 10. The construction of claim 1 wherein the top skin is a fluoropolymer film.
 11. The construction of claim 1 wherein the top skin is a member of the group consisting of metal foil and metal kraft paper laminates.
 12. The construction of claim 1 wherein the bottom skin is adhered is the membrane by an adhesive selected from the group consisting of neoprene, natural rubber, blended natural and synthetic rubber, epoxy resin, polyurethane and polyacrylate, polysulfide, silicone rubber, and asphaltic blends.
 13. A method of making an insulated laminated roof which comprises positioning a roof deck in place, adhering a water-impermeable membrane in superimposed position on said roof deck, and adhering a heat and actinic ray-resistant panel in superimposed position on said membrane, said panel being of foam interior construction and having adherent skins on its upper and lower surfaces.
 14. The method of claim 13 wherein said membrane is formed by applying an elastomeric precursor to the upper surface of the roof deck, and then polymerizing said precursor in situ.
 15. The method of claim 13 wherein said membrane is formed by applying a liquid emulsion of an elastomeric precursor to the upper surface of the roof deck and polymerizing said liquid emulsion in situ.
 16. The elastomeric of claim 13 wherein said membrane is formed by applying a solution of a pre-polymerized elastomeric precursor to the upper surface of the roof deck, and then evaporating the solvent.
 17. The method of claim 13 wherein said membrane is formed by applying an emulsion of a pre-polymerized elastomeric precursor to the upper surface of the roof deck, and then evaporating the carrier.
 17. The method of claim 13 wherein the membrane is formed by superimposing alternate layers of felt and either asphalt or bitumen on each other.
 18. The method of claim 13 wherein an adhesive is applied between the upper and lower surfaces of the membrane and the respective panel and roof deck.
 19. The method of claim 13 wherein the membrane is applied as a liquid precursor and forms its own adherent to the panel and roof deck as it polymerizes or dries,
 21. The method of claim 13 wherein said panel is formed from pre-fabricated parts sealed together in end-to-end relationship, each part comprising a foam body with a top and bottom skin. 